Recycling kit and method

ABSTRACT

A recycling kit including a container blank configured to be readily erectable to a recycling container is provided. A liner is attached to the recycling container. The liner has an open end and a sealed end. The sealed end of the liner is configured for insertion into the recycling container. A liner fastener is configured to close the open end of the liner. A shipping label is positioned on the recycling container.

TECHNICAL FIELD

This invention relates to recycling materials. More particularly, the invention relates to a kit used for recycling materials and a method thereof.

BACKGROUND OF THE INVENTION

Recycling is the reprocessing of old materials into new products. Recycling can achieve several goals such as preventing the waste of potentially useful materials, reducing the consumption of fresh raw materials, reducing energy usage, reducing air and water pollution, reducing the need for “conventional” waste disposal, and lowering greenhouse gas emissions as compared to virgin production. “Recyclable materials” or “recyclables”, may originate from home, business or industry. The recyclables may include glass, paper, metal, textiles and plastics. These materials are typically accumulated in containers, transported to a recycling center, sorted, cleaned and reprocessed into new products bound for manufacturing.

It would be advantageous if recycling methods and containers could be improved to make them more efficient.

SUMMARY OF THE INVENTION

According to this invention there is provided a recycling kit comprising a container blank configured to be readily erectable to a recycling container. A liner is attached to the recycling container. The liner has an open end and a sealed end. The sealed end of the liner is configured for insertion into the recycling container. A liner fastener is configured to close the open end of the liner. A shipping label is positioned on the recycling container.

According to this invention there is also provided a method of recycling materials, the method comprising the steps of providing a recycling kit, the kit comprises a container blank configured to be readily erectable to a recycling container, a liner is attached to the recycling container, the liner has an open end and a sealed end, the sealed end of the liner is configured to be inserted into the recycling container and a shipping label is positioned on the recycling container. The recycling container is erected from the container blank. The sealed end of the liner is inserted into the recycling container. Recyclable materials are inserted into the recycling container. The open end of the liner is closed. The top end of the recycling container is secured. The recycling container is shipped to a recycling facility. The recyclable materials contained in the recycling container are recycled.

According to this invention there is also provided a recycling kit comprising a container blank. The container is configured to be readily erectable to a recycling container. A liner is attached to the recycling container. The liner has an open end and a sealed end. The sealed end of the liner is configured to be inserted into the recycling container. A liner fastener is configured to close the open end of the liner. A shipping label is positioned on the recycling container. The recycling container is configured for disassembly into a flat package for shipping and reassembly into the recycling container.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank for use as a recycling container.

FIG. 2 is a perspective view of a recycling kit that includes the recycling container of FIG. 1.

FIG. 3 is a plan view of the bottom end of the recycling container, illustrating the first step in the erection of the bottom end.

FIG. 4 is a plan view of the bottom end of the recycling container, illustrating the second step in the erection of the bottom end.

FIG. 5 is a plan view of the bottom end of the recycling container, illustrating the final step in the erection of the bottom end.

FIG. 6 is a perspective view of the assembled recycling container ready for use.

FIG. 7 is a perspective view of an assembled, filled recycling container having a closed liner.

FIG. 8 is a plan view of the top end of the recycling container, illustrating the first step in the erection of the top end.

FIG. 9 is a plan view of the top end of the recycling container, illustrating the final step in the erection of the top end.

FIG. 10 is flow chart depicting the steps for processing the recycling kit, in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The description and drawings disclose a recycling kit and a method for processing the recycling kit and its contents. Referring to FIG. 1, a container blank, indicated generally at 10, is shown which will ultimately be folded into a recycling container.

As shown in FIG. 1, the container blank 10 includes panels 12, 14, 16 and 18. Each of the panels, 12, 14, 16 and 18, has a pair of depending self-locking flaps extending from the panels. For instance, panel 12 has a pair of flaps, 20 and 22, extending therefrom, the flaps being divided from the panel 12 by means of foldlines 24 and 26. Similarly, panel 14 has flaps 28 and 30 extending therefrom, with foldlines 32 and 34 forming the boundaries between the flaps 28 and 30 and the panel 14. In the same manner, panel 16 is shown having flaps 38 and 40 extending therefrom and the division in this instance being made by foldlines 42 and 44. Panel 18 is shown having flaps 46 and 48 extending therefrom such that the division of the panel 18 and the flaps 46 and 48 is made by foldlines 50 and 52. Panel 18 has a seal flap 54 extending therefrom wherein foldline 56 forms the division between the seal flap 54 and the panel 18. As further shown in FIG. 1, panels 12, 14, 16 and 18 are divided by foldlines 58, 60 and 62.

Referring again to FIG. 1, flap 20 includes recess 66. The recess 66 of flap 20 forms tabs 68 a and 68 b. Similarly, flap 38 includes recess 70. The recess 70 of flap 38 forms tabs 72 a and 72 b. In the same manner, flap 30 includes recess 74. The recess 74 of flap 30 forms tabs 76 a and 76 b. As further shown in FIG. 1, flap 28 includes openings 78 a and 78 b. Similarly, flap 46 includes openings 80 a and 80 b. Referring again to FIG. 1, flap 48 includes tab 82, flap 40 includes tab 84 and flap 22 includes tab 86.

The blank 10 is made of a corrugated material and is configured for reuse as a recycling container. In the illustrated embodiment, the blank 10 is made of recycled polymer material originating as post consumer waste, such as for example polypropylene or polypropene. In other embodiments, the blank 10 can be made of other materials, such as for example virgin polymer material or corrugated cardboard having a fluid resistant coating, sufficient for reuse as a recycling container. The corrugated material used for the blank 10 illustrated in FIG. 1 has a thickness in a range of from about 4.0 mm to about 5.0 mm. Alternatively, the material used for the blank 10 can have a thickness greater than about 5.0 mm or less than 4.0 mm.

As shown in FIG. 2, the blank 10 is joined together to form recycling container 100. In the illustrated embodiment, the outside surface of the seal flap 54 is bonded to the inside surface of the panel 12. The seal flap 54 can be bonded to the panel 12 in any suitable manner, such as for example ultrasonic welding or adhesives. The recycling container 100 has a height h, a width w and a depth d. In the illustrated embodiment, the height h is approximately 29.5 inches, the width w is approximately 13.5 inches and the depth d is approximately 13.5 inches. Alternatively, the height h can be more or less than approximately 29.5 inches, the width w can be more or less than approximately 13.5 inches and the depth d can be more or less than approximately 13.5 inches.

The recycling container 100 includes a liner 102 attached to one of the panels 12, 14, 16 or 18. The liner 102 is attached to a panel such that the liner 102 can be later removed and inserted into the container. In the illustrated embodiment, the liner 102 is attached to the panel 18 using strips of tape 104. In other embodiments, the liner 102 can be attached to a panel in other suitable manners, such as for example, adhesives, pouches or covers. The liner 102 will be discussed in more detail below.

Referring again to FIG. 2, the recycling container 100 also includes a liner fastener 106. The liner fastener 106 is configured to maintain closure of the open end of the liner 102 once the liner 102 is filled with recyclable materials and the liner 102 is closed. In the illustrated embodiment, the liner fastener 106 is a zip tie. In other embodiments, the liner fastener 106 can be other mechanisms or devices, such as for example a twist tie, a cable tie, a clip, a clamp, or tape, sufficient to maintain closure of the open end of the liner 102 once the liner 102 is filled with recyclable materials and the liner 102 is closed. In the embodiment shown in FIG. 2, the liner fastener 106 can be attached to the recycling container 100 using the strips of tape 104. In other embodiments, the liner fastener 106 can be attached to the recycling container 100 using other suitable manners, such as for example with an adhesive. In yet other embodiments, the open end of the liner 102 can be closed by other suitable methods without the use of a liner fastener 106, such as for example, tying the open end of the liner 102 into a knot.

Referring again to FIG. 2, the recycling container 100 includes a shipping label 108. The shipping label 108 is configured to provide the necessary information for shipping the recycling container 100 to a desired recycling facility, such as for example the recycling facility address, the container weight and user identification information. In one embodiment, the shipping label 108 can include this information and additional information in the form of scannable bar codes. In the illustrated embodiment, the shipping label 108 is positioned on the recycling container 100 such that the necessary shipping information is readily visible on the recycling container 100. In other embodiments, the shipping label 108 can be positioned on the recycling container 100 in other methods, such as for example in a removable pouch, for reattachment to the recycling container 100 at another time. Optionally, the shipping label 108 can be covered with a protective covering for protection from environmental conditions. In the illustrated embodiment, the shipping label 108 has a protective covering 110 comprising clear tape. Alternatively, the protective covering 110 can be other materials, such as for example a protective polymer film. In yet other embodiments, the shipping label 108 can be omitted and the shipping information can be printed directly on the container blank 10.

As shown in FIG. 2, the recycling container 100 contains optional indicia 112. The optional indicia is 112 is configured to convey various messages to the user. Examples of messages that can be conveyed include: the logo of the user's company, instructions for using the recycling container 100, approved recycling materials, and the international recycling symbol. While the recycling container 100 illustrated in FIG. 2 shows indicia on panel 18, it should be understood that the indicia can be positioned on the recycling container 100 in any suitable location.

The combination of the elements of the recycling container 100, the liner 106, the liner fastener 106, and the shipping label 108 form recycling kit 120.

The recycling kit 120 is used in a recycling method 200 as illustrated in FIG. 10. In step 210 of the method 200, a user receives a quantity of recycling kits 120. The quantity of recycling kits 120 initially received by the user can vary depending on the anticipated use of the recycling kits 120. As previously described, each recycling kit 120 includes a liner 102, a liner fastener 106 and a prepaid shipping label 108. In the illustrated recycling method 200, the recycling kits 120 are shipped to the user in a flat package, such that the recycling containers 100 are in an unerected or knocked-down condition. In another embodiment, the recycling kits 120 can be shipped to the user such that the recycling containers 100 are in an erected condition.

Upon receipt of the recycling kit 120 by the user, the recycling container 100 is prepared for use by the user in step 220. Initially, the bottom end of the recycling container 100 is secured by the erection operation illustrated in FIGS. 3-5. The erection operations illustrated in FIGS. 3-5 are configured to be readily accomplished by hand and without the use of tools. As shown in FIG. 3, flap 28 having recess 74 and tabs 76 a and 76 b is folded inward to a position substantially perpendicular to the panel 14. Next, as shown in FIG. 4, flaps 22 and 40 are folded over flap 28. In the folded positions, flaps 28, 22 and 40 cooperate to form slot S. Lastly, as illustrated in FIG. 5, flap 48 is folded over the flaps 28, 22 and 40 such that the tab 82 of flap 48 is inserted into the slot S. Insertion of the tab 82 of flap 48 into the slot S sufficiently secures the bottom end of the recycling container 100 such that the recycling container 100 is structurally ready for use. As described above, the flaps 22, 30, 40 and 48 cooperate to form self-locking flaps. Optionally, the bottom end of the recycling container 100 can be further secured by taping over the flap 48 and the slot S. However, taping the flap 48 and the slot S is not necessary to closing the bottom end of the recycling container 100.

Referring again to step 220 in FIG. 10, the next step in preparing the recycling container 100 for use is the deployment of the liner 102. The liner 102 has an open end and a sealed end. As shown in FIG. 6, the liner 102 is removed from the panel, 12, 14, 16 or 18 and the sealed end of the liner 102 is inserted into the interior of the recycling container 100. The liner 102 is configured to retain the contents of the recycling container 100. In the illustrated embodiment, the liner 102 is made of a polymeric material, such as for example polyethylene and has a thickness in a range of from about 3.0 mm to about 5.0 mm. In other embodiments, the liner 102 can be made of other materials, such as for example polylactic acid, sufficient to retain the contents of the recycling container 100, and can have a thickness greater than about 5.0 mm or less than 3.0 mm.

Referring again to step 220 in FIG. 10, after the liner 102 is deployed into the interior of the recycling container 100, the user can start to insert recyclable materials into the recycling container 100. Examples of recyclable materials include copy and notebook paper, envelopes, newspapers, magazines, plastics having numbers 1-7 on the container, milk and juice containers, glass containers, aluminum and tin food cans, cosmetics containers, and stretch wrap. Other recyclable materials can also be put into the recycling container 100. While the embodiment illustrated in step 220 provides for various recyclable materials to be inserted into the same recycling container 100, it is within the contemplation of the recycling kit that specific recycling materials could be inserted into specific recycling containers 100. As one example, a specified recycling container 100 could be designated specifically for newspapers and another specified recycling container 100 could be designated specifically for glass containers.

Next, as shown in step 230 in FIG. 10, the user fills the recycling container 100 with recyclable materials until the container is substantially full. As shown in FIG. 7, the liner 102 is closed by use of the liner fastener 106 as described above. Once the liner 102 is closed, the top end of the recycling container 100 is secured by the erection operations illustrated in FIGS. 8 and 9. The erection operations illustrated in FIGS. 8 and 9 are configured to be readily accomplished by hand and without the use of tools. As shown in FIG. 8, flap 28 having openings 78 a and 78 b, and flap 46 having openings 80 a and 80 b, are folded inward to a position substantially perpendicular to the panel 14. Next, as shown in FIG. 9, flap 70 is folded over flaps 28 and flap 46 such that the tabs, 72 a and 72 b, are inserted into the opening 80 a of flap 46 and opening 78 b of flap 28, respectively. Similarly, flap 66 is folded over flaps 28 and flap 46 such that the tabs, 68 a and 68 b, are inserted into the opening 80 b of flap 46 and opening 78 a of flap 28, respectively. Insertion of the tabs, 72 a, 72 b, 68 a and 68 b into openings 80 a, 78 b, 80 b and 78 a respectively sufficiently secures the top end of the recycling container 100 such that the recycling container 100 is structurally ready for shipping. As described above, the flaps 20, 28, 70 and 46 cooperate to form self-locking flaps. Optionally, the top end of the recycling container 100 can be further secured by taping over the flaps 66 and 70, however taping the flaps 66 and 70 is not necessary to the practice of the invention.

Once the top end of the recycling container 100 is secured in step 230, the recycling container 100 is ready for shipping. In one embodiment as shown in step 240 in FIG. 10, the user requests a pick-up from a delivery service. The delivery service secures the recycling container 100, and using the information on the shipping label 108, transports the recycling container 100 to the indicated recycling facility. Examples of delivery services include United Parcel Service (UPS) and Federal Express. In the illustrated embodiment, the cost of the shipping of the recycling container 100 has been prepaid and is indicated on the shipping label 108. Alternatively, the cost of the shipping of the recycling container 100 can be paid at the time of shipping. The recycling container 100 is shipped to the recycling facility indicated on the shipping label 108. In one embodiment, the recycling container 100 can be shipped to a nearby recycling facility. In other embodiments, the recycling container 100 can be shipped to any recycling facility in a network of facilities or the recycling container 100 can be shipped to a facility specializing in recycling the specific materials in the recycling container 100.

As indicated in step 250 in FIG. 10, after the recycling container 100 is shipped to the recycling facility, the contents of the recycling container 100 are sorted, weighed and recycled. The recycling container 100 is prepared for reuse as a recycling container by disassembly into a flat package for shipping to a user. In one embodiment, the recycling container 100 can be disassembled by debonding the seal flap 54 from the panel 12. In other embodiments, the recycling container 100 can be shipped as a flat package with the seal flap 54 still bonded to the panel 12.

As shown in step 260, a summary of the recycled materials is optionally prepared and sent to the user. In one embodiment, the user receives a summary report, for a specified period of time, indicating the amount (in pounds) of the various materials, such as for example, glass, paper, plastic, and/or aluminium, that have been recycled. In other embodiments, the report can include other information including the user facilities involved, year-to-date or cumulative totals, and period-to-period changes.

As indicated in step 250 in FIG. 10, as the initial quantity of recycling kits 120 declines and the quantity of unused recycling kits 120 reaches a pre-determined reorder point, the user orders replacement recycling kits 120. In one embodiment, the user is shipped new replacement recycling kits 120 that may comprise reused recycling containers 100. Alternatively, the replacement recycling kits 120 may comprise new recycling containers 100.

The recycling kit 120 and recycling method 200 described above provide many advantages. For example, the recycling method 200 provides for ready recycling of recyclable materials for multi-user facilities, such as for example commercial and retail businesses. The recycling kit 120 and the recycling method 200 allows recycling at a large number of user facilities located nationwide in an extremely convenient and user-friendly process, entailing minimal time commitment and training. Additionally, the recycling kit 120 and the recycling method 200 involves the users directly in the recycling process through receiving the recycling kits, substantially filling the recycling kits, and shipping (at their discretion) directly to a recycling facility.

The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope. 

1. A recycling kit comprising: a container blank configured to be readily erectable to a recycling container; a liner attached to the recycling container, the liner having an open end and a sealed end, the sealed end of the liner configured to be inserted into the recycling container; a liner fastener configured to close the open end of the liner; and a shipping label positioned on the recycling container.
 2. The recycling container of claim 1, in which the container blank is readily erectable to a recycling container by hand and without the use of tools.
 3. The recycling container of claim 1, in which the container blank is made of corrugated post consumer waste material.
 4. The recycling container of claim 3, in which the corrugated post consumer waste material is a thermoplastic.
 5. The recycling container of claim 4, in which the corrugated thermoplastic post consumer waste material has a thickness is a range of from about 4.0 mm to about 5.0 mm.
 6. The recycling kit of claim 1 in which a shipping cost is prepaid.
 7. The recycling kit of claim 1, in which indicia is positioned on the recycling container.
 8. The recycling kit of claim 7, in which the indicia is a company logo.
 9. The recycling kit of claim 1, in which the recycling container is readily disassembled into a flat package for shipping and reassembled into the recycling container.
 10. The recycling kit of claim 1, in which the liner fastener is a zip tie.
 11. The recycling kit of claim 1, in which the shipping label includes a scannable bar code.
 12. A method of recycling materials, the method comprising the steps of: providing a recycling kit, the kit comprising: a container blank configured to be readily erectable to a recycling container; a liner attached to the recycling container, the liner having an open end and a sealed end, the sealed end of the liner configured to be inserted into the recycling container; and a shipping label positioned on the recycling container; erecting the recycling container from the container blank; inserting the sealed end of the liner into the recycling container; inserting recyclable materials into the recycling container; closing the open end of the liner; securing the top end of the recycling container; shipping the recycling container to a recycling facility; and recycling the recyclable materials contained in the recycling container.
 13. The method of claim 12, in which feedback is provided as to the recycled materials.
 14. The method of claim 12, in which the container blank is readily erectable to a recycling container by hand and without the use of tools.
 15. The method of claim 12, in which a cost of shipping the recycling container to a recycling facility is prepaid.
 16. The method of claim 12, in which the recycling container is readily disassembled into a flat package for shipping and reassembled into the recycling container.
 17. The method of claim 12, in which indicia is positioned on the recycling container.
 18. A recycling kit comprising: a container blank configured to be readily erectable to a recycling container; a liner attached to the recycling container, the liner having an open end and a sealed end, the sealed end of the liner configured to be inserted into the recycling container; and a shipping label positioned on the recycling container; wherein the recycling container is configured for disassembly into a flat package for shipping and reassembly into the recycling container.
 19. The recycling kit of claim 18, in which the container blank is made of corrugated post consumer waste polymer material.
 20. The recycling kit of claim 19, in which the corrugated polymer post consumer waste material is a thermoplastic. 